Synchronous Technology A New Paradigm in 3D Design

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1 Synchronous Technology A New Paradigm in 3D Design R. L. Plummer MS Systems Management University of Southern California (USC) Principal / Systems Consultant Archway Systems Inc. Huntington Beach, CA ABSTRACT - Synchronous Technology (ST) is a dramatic breakthrough in Computer Aided Design (CAD) that will change the way engineers approach product design and create a new paradigm in Engineering Education by providing tools that allow students to focus more on what they want to model rather than how they want to model. As noted by Dr. Ken Versprille (April 2008), ST is a history-free, feature based modeling system that combines the best of dimension and constraint driven techniques for full control and repeatability, with the flexibility of direct modeling A 100x design speed improvement could be a conservative estimate. This paper will introduce and summarize some of the key features and benefits of this amazing new technology against the backdrop of traditional CAD and examine some of its remarkable and well documented improvements in design productivity and what this could mean for industry and education. I. What is Synchronous Technology Synchronous Technology is a patent pending, proprietary software application layer available in Siemens Solid Edge and NX software products. During Siemens acquisition of UGS Corporation, it was discovered that their engineers were working on a technology that would fundamentally change the way manufacturers design and develop products, allowing them to deliver innovation faster than ever before. Siemens accelerated development and testing of this new technology and were able to create a system that simultaneously synchronizes model geometry and behavior rules and brings them all together with new decision logic into a single software engine. The results are a design experience that: 1) Allows automatic selection of geometry based on function or condition. 2) Allows feature parameter manipulation without ordered regeneration. 3) Allows edits to geometry regardless of creation order. 4) Eliminates many issues with parent/child features. 5) Allows dimensional directional control not possible in history based systems. 6) Allows editing of outsourced CAD data up to 50 or 100 times faster than the system it was created in. II. A Look Back at CAD Over the past 45 years, Computer Aided Design has seen many advances (see Figure 1). 2D digital drafting of the early 1960 s let to 3D wireframe and surface modeling technology in the 70 s. CAD technology remained classified as explicit modeling because of the need to edit lines and curves in the outer boundaries of the 3D model. In the early 80 s, solid modeling solutions remained explicit because of the reliance on

2 Boolean operations of union, subtract and intersection. This all changed in the mid 1980 s with the emergence of parametric modeling and the beginning of model features being embedded in a sequential history-based architecture. Throughout the 1990 s, and into the 21 st century, most CAD applications adopted this parametric, feature, history-based approach. Evan Yares (2008) believes that Parametric modeling can be incredibly powerful, but does little to help users deal with dumb or imported models. For this, the essential method is explicit modeling. The basic concept is pretty simple; editing operations are made directly to the boundary representation model. The end result of direct editing is a dumb solid model one with no parameters or features. Synchronous Technology is transformative in that it allows a dumb model to become smart because the system is able to infer the design intent. This represents an important breakthrough in the CAD industry as seen in Figure 2. What Siemens has created with Synchronous Technology is the best of both approaches deep, insightful examination of the current geometry conditions of a model, joining that information together with user-defined constraints and parametrically driven dimensions, and then localizing dependencies in real time. How CAD has Evolved Figure 1. History of CAD.

3 2008 Synchronous Technology creates a New Paradigm in CAD Design Figure 2. Synchronous Technology a New Paradigm. III. Capturing Ideas as you think of Them Driving design with 3D Dimensions - Engineers and designers are forced to use precious time pre-planning designs for future use. In Figure 3, below, the designer wants to add geometry to the model while maintaining the position of the hole from the base but he cannot. Figure 3. Need to Add a Base. Figure 4. Can t Change Hole Location. Synchronous Technology allows users to add 3D driving dimensions anytime during the design process, so design requirements can be established as needed (see Figure 5). In traditional CAD, this simply isn t possible as illustrated in Figure 4 and you would have to redraw or recreate the hole again losing valuable time.

4 Selecting a Region Figure 5. Driving Dimensions with ST. 3D driving dimensions can be locked, dynamic, based on equations and linked to spreadsheets so parts can be configured as needed using a wide variety of engineering practices. If intent needs to be redefined, a simple drag drop of a dimension from one part of a model to another can be performed. Steering Wheel Special Editing Tools A critical area of concern for all mechanical designers is how to respond effectively to customer requests for change. The new editing tools in ST allow designers to make changes much quicker to meet tight deadlines. To speed up this process, sketching and modeling are contained in a single design environment so after drawing you use grab and go handles to turn design regions into a 3D model. You can sketch in 3D space or directly on the model and intent is implied based on cursor position. Sketches become consumed and are no longer needed because the edits are made directly to the 3D model. Upon selection of a 3D face, a special multi-purpose handle called a steering wheel is displayed for immediate action (Figure 6). Move, rotate or align 3D geometry by pulling or enter exact values for precise control. Figure 6 Grab and Go Tools. Feature Collection ST actually stores model features (holes, rounds, cutouts, etc.) as a collection and not in a linear (order dependent) tree like traditional parametric modeling systems that required model regeneration when changes are made. With ST, you can can organize and edit features as fast as you can move your mouse. This ability to collect features allows you to sort and group features by name or by type. This increases productivity because you can now easily group rounds, holes and cutouts together regardless of when they were created (see figure 7 below). What this means for the designer / engineer is that no regeneration of the model is required when

5 features are edited. Features can instantly be eliminated and new ones created by simply sketching them on the model. Material can be added or subtracted by highlighting a sketch region and stretching/shrinking with a mouse or typing in precise dimensions. You can even modify operations that occurred very early on during model creation. All of this adds up to significant time savings and productivity gains. The spreadsheet below (Figure 8) is representative of the time savings realized with Synchronous Technology. What this means for the designer / engineer is that no regeneration of the model is required when features are edited. Features can instantly be eliminated and new ones created by simply sketching them on the model. Figure 7. Sorting Features in ST. Up to a 100x Design Speed Experience with ST Task Traditional Technology Synchronous Technology Strategize the edit (add feature, edit existing) 60 seconds 0 seconds Locate feature for edit 5 0 Roll model to feature for edit 5 0 Add draft face operation 30 5 Recompute from new draft 10 0 Discover an error 15 0 Strategize the fix (new plane, from other ) 30 0 Create vertial plane and reorder 30 0 Edit boss to new plane 30 0 Recompute rest of model 5 0 Total Time 3.7 minutes 5 seconds Figure 8. Time Savings with ST.

6 IV. Changing Models as You Change Your Mind Fast Edits Traditional CAD tools force change in the same manner as creating data, so users must spend precious design time just understanding how the model was created. Because of the history approach, models must be constrained in a specific way and usually not the way needed so you can expect to spend time fixing broken features downstream from the change. The most desirable and natural way to edit is to change the geometry itself and not some underlying constraint system, an unrelated feature or a parent sketch. So how can Synchronous Technology let you change your model as fast as you can change your mind? You are able to grab large portions of a model and move it with little effort. Making these drastic changes without regard to how the model was constructed offers tremendous flexibility because modifications aren t limited by creation methods as shown in Figure 10 below. For example, if you want to move a hole or slot, you can move that feature directly. Making this same change in a traditional CAD system will force an edit to some parent feature. Changes are shown in real-time regardless of model size. Changing a Model as Fast as You Can Change Your Mind Figure 10 Fast Edits in ST.

7 Live Rules - A unique concept in Synchronous Technology is Live Rules. This capability automatically finds and maintains geometric conditions during a drag or even a dimensional edit (Figure 9). History based CAD systems require even the most obvious geometric conditions to be called out with constraints so changes outside that definition can t be accomplished. With Live Rules the system is smart enough to recognize conditions such as concentric, tangent, symmetric, horizontal, vertical and even coplanar and keep those conditions during edits. The Engineer is able to capture a feature like a hole and move it into position to meet a pin or shaft while the rest of the model reacts predictably. Since features are not dependent on each other, users can move any elements in the model. Live Rules finds and maintains concentric and tangent elements and can be configured to maintain more or less conditions, such as keeping faces horizontal or vertical. Other systems don t allow these types of edits because holes are driven from other features. By temporarily suspending Live Rules, you can easily drag just an interior face even if a series of cuts was made with a single feature. No matter which faces are selected, live rules finds and maintains critical geometric conditions. Live Rules automatically finds and maintains geometric conditions during drag or dimensional edits Move only the red hole and get the exact results you need even with NO relationships Figure 9. Live Rules in ST.

8 3D Driving Dimensions With ST, 3D driving dimensions can be added to any part of a 3D model, not just sketch elements. Thus, you have the ability to control the position of geometry that was created earlier in the process. Dimensions can be linked to spreadsheets or you can build formulas to relate one dimension to another. 3D model constraints can be used to modify geometry and make elements perpendicular, tangent or parallel and that relationship can be saved to keep the users rules. Because features and geometry are not dependent on each other, users can change either element and the other will react accordingly regardless of creation order. In the index block example (Figure 10), dimensions were applied directly to the 3D model and allow immediate change. Although the index guide was one of the last features created, it can actually drive the overall size as the direction is toggled. To fix critical distances, dimensions can be locked but still allow edits as shown in red. Dimensions can have any number of equations or be linked to spreadsheets for building configurable parts. Even the hole can be changed from threaded to a counter-bore. Live rules maintain model integrity and locked 3D driving dimensions preserve distances. No other CAD system in the world allows you to make direct edits but have precise dimensional control. 3D Driving Dimensions allow Immediate Change to 3D Model Figure 10.1 Increasing the angle. Figure 10.2 locking in critical dimensions. Figure 10.3 Centering and Redefining the Hole.

9 Feature Parameter Manipulation Without Order Regeneration While features don t need to be edited in the same manner as they were created, there is a certain class of features where it makes sense. Holes are the most common where users often need to change the type from simple to counter bore. After performing a thin-wall operation, being able to change its thickness is another good example. These are called procedural features and are significantly smarter than features in any other system. These ST features are unique to the CAD industry. While history based systems have been able to do this for many years, they suffer performance issues as all subsequent operations need to be regenerated even if the change is an isolated part of the model. Procedural features in ST allow modification of features with no model regeneration. The system uses a localized solve and only updates the minimum geometry required to get results from the Change. Because features are not dependent, you can make direct modifications to any of the pattern instances and all occurrences will immediately reflect that change. For example, to increase the aesthetic look of the slot array in Figure 11 below, traditional CAD systems require changes to the parent feature and must regenerate all downstream operations. In ST, Features are not dependent on each other, so you have total flexibility in placing dimensions to any element when most convenient. By adding a dimension from the center of the wheel to one of the slots, we can change the size and position of all pattern instances. Synchronous Technology is the only CAD system where you can make parameterized edits without complete model regeneration.. Changing Pattern Instances, Length, Style and Angle Figure 11.1 Changing Pattern Instances. Figure 11.2 Changing Pattern Length, Style and Angle.

10 V. Synchronous Technology in a Multi-CAD World Most CAD systems can share data through neutral exchange formats such as STEP or IGES. Some systems even simplify the translation and read the CAD data directly skipping the Save As step. However, that s where the simplicity ends. This is a nagging problem for designers and engineers because there is often no effective way to edit imported geometry or include it in existing geometry. In ST, the same levels of edit capabilities are available for imported models as for native files. Faces or complete face sets can be copied, moved, rotated or deleted. For precise control, dimensions can be used even thougth imported geometry may be dumb with no stored relationships or features. Live rules in ST recognizes geometric relationships within the imported model to ensure predictable edits. Procedural features can be added at will and the same synchronous solve technology manages the changes to any geometric element. For example, you can add dimensions between mounting holes in an imported model, enter a desired value, and the correct hole spacing will be obtained. As shown in Figures 12 and 13, parts from three different CAD systems are used to create a vise assembly. The jaw plate comes from AutoDesk Inventor and doesn t fit. However, with ST, you can align the faces and create geometric relationships like symetry. The overall shape is maintained by preserving concentric and tangent conditions. The movable jaw came from SolidWorks and is missing some key features. With the tools in ST, you can easily copy data between models from different CAD systems. The vice plate was created in Siemens Solid Edge and contains features that will be duplicated on the SolidWorks part. Since features have no dependency, you are able to simply move holes and the model will follow. Geometry across different assembly components is free from dependency. The result is a design experience that allows you to edit imported CAD data faster (often much faster) than the system it originated from. Autodesk Jaw Plate Solid Works Movable Jaw Solid Edge (ST) Vice Plate Figure 12. Imported Data in ST.

11 Fast Importing and Modifying of Foreign CAD Files Align Autodesk Jaw Plate Add Features to SolidWorks Blend Solid Edge Features into Movable Jaw SolidWorks Movable Jaw 15 seconds 5 seconds 30 seconds Copy feature from Jaw plate Attach Feature to Jaw Select, align and reposition 10 seconds 25 seconds 10 seconds Select face Select co-planar surface Stretch to desired width 5 seconds and base features 15 seconds 10 seconds Figure 13 - From Imported Files to Finished Assembly in 2 minutes!!

12 VI. Combining 3D with the simplicity of 2D Designers proficient in 2D drawing often need to edit Engineers 3D models. Engineers and analysts need to test parts against requirements and manuafacturing may need to adjust a blend radius to reduce fabrication costs not to mention all the what if experiments carried out in product development. Synchronous Technology helps to make experts out of non-engineers by allowing them to create designs in the same environment with unified 2D and 3D commands. It helps to bridge the gap between 2D and 3D by including faniliar concepts such as fence select and stretch (Figure 14/15). If you need to move a set of features or faces, fence them in and drag them to a new location. The analyst testing a proof of concept can now make a stiffening rib stronger by just draging a face. ST provides hot keys for quickly snapping models to a top or side view, 3D stretching on parts and assemblies is just that much easier. With this capability, you can snap to a front view, fence half the model and stretch it into position without having to find and edit the appropriate feature (if that were even possible) and fixing any downstream failures. ST will automatically maintain geometric conditions with Live Rules and if there are any 3D driving dimensions to control fit and position, those will be maintained as well. Figure 14 - Example of 2D Stretch into 3D Model Update. Figure 15 Stretching in 3D as if they were 2D.

13 VII. ST s impact on Design Productivity Performance improvements realized by synchronous technology for edits on history based models will resultin dramatic development process gains (Dr Ken Versprille, 2008) and product manufactuing companies will see: Decreased time to revenue based on reduce development cycles. Increased ease in coping with expected and unexpected product change. An opportunity to work on product models they did not originally author. Dramatic improvement in the supply chain because design intelligence can be transferred between different CAD systems. Increased capabilities exploring alternative designs at a much faster rate. The ability to reuse designs without remodeling. An ability to react faster to market requirement changes much later in the development cycle. This all translates into very good news and a big boost in productivity for design and manufacturing companies (see Figure 15). The robust features and functions in Sybchronous Technology will allow designers and engineers to innovate and excel in a brand new and very exciting interactive design environment. Task Traditional Technology Figure 15 Productivity Improvements with ST. Synchronous Technology Strategize the edit (edit dimension) 60 seconds 0 seconds Locate feature to edit 20 0 Edit feature 60 5 Regenerate model 30 0 Inspect model for dowstream failures Fix failed features Time 20.8 minutes 5 seconds

14 VIII. Synchronous Technology s impact in Education More and more technologies are required to be taught in engineering schools with seemingly less and less time available for educators to devote time to leaning, developing curriculum and ultimately transferring this knowledge to their students. Many students find that they must take five years to complete the bachelor s degree in mechanical or manufacturing engineering. Anything that can be done to make the learning process more productive has to help. Synchronous Technology may enable shortening classes in solid modeling or increase the number of projects done in a class, either of which would contribute to the productivity of learning. Coupled with automated drafting modules available from Siemens and other CAD manufacturers, it may even be possible to eliminate a basic CAD class where much time is spent learning the steps required to create and edit models. This would enable both the professor and student to spend more time on product design focusing on what and not how they want to model. IX. Conclusion Siemens Corporation has created a new paradigm in 3D Design with Synchronous Technology. It sets a new standard for mechanical CAD software providers, offering designers, engineers and educators more capability, flexibility, speed and freedom in 3D modeling than ever before. Many Industry analysts and CAD enthusiasts believe ST is the greatest CAD breakthrough in the last 25 years. It allows Engineers to rapidly test out and validate new ideas with 3D driving dimensions, robust editing tools and feature collections that don t require model regeneration. Live Rules allow the engineer to change their mind and quickly test out new modeling scenarios at unheard of speed because geometric conditions of the models are identified and maintained. ST can edit imported data from any CAD system and turn dumb solids into parts with features that can be copied from model to model. And this can be done quicker than in their native CAD software. Siemens Synchronous Technology has combined the best of explicit and feature/history based CAD systems and created a marvelous new approach to 3D design one that will no doubt have their competitors scrambling to catch up. X. References Versprille, Dr. K. (2008) Synchronous Technology, white paper prepared by Collaboration Product Development Associates, LLC. Yares, E. C. (2008) Synchronous Technology and Design Freedom, commentary by Evan Yares on the tools that engineers use to shape our world. Siemens Corporation Publications (2008) 10 Reasons to Select Solid Edge with Synchronous Technology, (2008) Solid Edge with Synchronous Technology, Solid Edge with Synchronous Technology, the biggest breakthrough in CAD seen in the last 20 Years.